Apparatus and process for severing flexible sheet materials

ABSTRACT

An improved apparatus and process for continually severing continuous flexible sheet material, particularly smokable sheet materials, into discrete pieces having a parallelogram configuration is described.

United States Patent n 1 Honeycutt et al.

APPARATUS AND PROCESS FOR SEVERING FLEXIBLE SHEET MATERIALS Inventors: James R. Honeycutt; Thomas F.

Friday, both of Charlotte; Terry S. Floyd, Matthews, all of N.C.

Assignee: Celanese Corporation, New York,

Filed: June 30, 1971 Appl. No.: 158,198

U.S. Cl. ..83/35, 83/47, 83/167,

83/408 Int. Cl. ..B20d 11/00 Field of Search.. ..-.....83/35, 47, 167, 408

[ 1 Jan. 30, 1973 [56] References Cited UNITED STATES PATENTS 1,340,225 5/l920 Howard ..83/35 X 2.836.018 5/l958 Key 83/47 X 3,224,306 12/1965 Hawley et al. ..83/408 X 3,329,049 7/1967 Hubbard ..83/47 Primary ExaminerDonald R. Schran Attorney-Thomas J. Morgan et al.

[ ABSTRACT An improved apparatus and process for continually severing continuous flexible sheet material, particularly smokable sheet materials, into discrete pieces having a parallelogram configuration is described.

9 Claims, 1 Drawing Figure PATENTEDJAN 30 I975 INVENT OR JAMES R. HONEYCUTT THOMAS F. FRIDAY TERRY S. FLOYD APPARATUS AND PROCESS FOR SEVERING FLEXIBLE SHEET MATERIALS BACKGROUND OF THE INVENTION Many commercial processes require the cutting of flexible sheet materials into discrete pieces in the conversion of the sheet materials into desired articles of manufacture. These cutting operations may be found in the processing of paper sheets, fibrous webs, plastic film, and the like. The present invention pertains to the cutting of these flexible sheet materials, and especially to the cutting of flexible sheet materials used in the manufacture of smokable articles.

Filler material for cigarette and cigars is generally composed substantially of shredded tobacco leaf. Many of these fillers also contain significant amounts, e.g., up to about 20 percent of reconstituted tobacco shred. In addition, there is an increasing interest by the industry in the incorporation of tobacco replacement materials into the composition. The term reconstituted tobacco encompasses materials prepared by two different processes. First, wet process reconstituted tobacco is prepared by finely grinding tobacco particles in the presence of a high moisture content and then forming a sheet, the coherence of which is achieved through the naturally adhesive properties of the tobacco. Dry process reconstituted tobacco is prepared by combining with finely ground tobacco a minor amount of a binder material and usually a minor amount of a combustion modifier and then casting a sheet of the mixture.

Tobacco replacement materials are substantially non-tobacco in composition but tend to simulate the properties of tobacco in appearance, burning rate, etc. These materials are normally comprised of a combustible substrate, usually cellulosic in nature, in combination with one or more conventional combustion modifiers. Other ingredients may be added to impart particular properties to the composition. These materials are usually prepared in the form of a cast film or a paper-like sheet.

For the purpose of the present description, reconstituted tobacco and tobacco replacement materials will be generically referred to as smokable sheet materials.

Utilization of smokable sheet materials has a considerable number of advantages for the manufacturer and the ultimate consumer. Among such advantages are increased product uniformity, increased ease of manufacture and reduced cost. In the case of some tobacco replacement materials, an additional advantage is a reduction in the tar and nicotine content of the ultimate smoking product.

Smokable sheet materials are normally blended with tobacco leaf prior to the shredding operation in the manufacture of cigarettes or the thrashing step in the manufacture of cigars. Since smokable sheet materials are manufactured in the form of a wide, e.g., from about 24 to about 72 inch continuous sheet, it is necessary prior to this blending to cut the sheet material into dimensions of a suitable size, e.g., l to inches on a side. It has been found that this cutting preferably occurs at the time of manufacture of the material since it is more readily and economically shipped in the cut state.

Prior art cutting apparatus employed for this purpose have proven to be unsatisfactory since cutting with these devices tends to cause fragmentation or tearing of the sheet material. In addition, with some of these materials, particularly those containing combustion modifiers, the cutting blades in such devices require frequently sharpening because of the abrasive nature of the sheets. Furthermore, these devices tend to be capable of cutting only at relatively low speeds and in many instances, require a discontinuous cutting operation.

Also, many devices operate at an objectionable noise level. In order to obtain the advantages accruing from the use of smokable sheet materials, an apparatus and process for continuously cutting ,the sheet into processable pieces at high speeds, e.g., 250 ft./min. or greater, is needed. 4

SUMMARY OF THE INVENTION It is an object of the present invention to provide an improved apparatus for continuously cutting flexible sheet materials, particularly smokable sheet materials, at high speeds.

Another object is to provide an improved process for cutting of these materials.

Other objects, if not specifically set forth herein, will be obvious to the skilled artisan upon a reading of the present specification, taken in conjunction with the drawing.

DRAWING The drawing is a perspective view of an apparatus achieving the objects of the present invention.

DETAILED DESCRIPTION OF THE INVENTION Generally, the objects of the present invention are achieved by conveying a continuous sheet of flexible material, e.g., a smokable sheet material, in a first direction to a severing zone, severing the sheet material into a plurality of continuous parallel strips, crosslapping the strips onto a continually moving zone traveling in a direction transverse to the first direction, conveying the strips to a second severing zone, and generally transversely severing the strips to form discrete pieces having a parallelogram configuration.

The steps of a preferred embodiment of the present invention are set forth in the following detailed description and are to be considered in conjunction with the appended drawing described generally hereinabove of an apparatus for use in the practice of the present invention.

In the preferred embodiment, a smokable sheet material or other flexible sheet material 10, preferably having a moisture content of from about 8 to about 12 percent to facilitate cutting, is conveyed by first conveyor means 12, shown in the drawing as an endless conveyor belt, to severing means 14 where the sheet is severed into a plurality of continuous parallel strips. In the drawing, severing means 14 is shown as a plurality of slitter blades. These blades cut by means of a scissorlike action between the upper and lower banks of blades. Slitter blades are known in the cutting art. Instead of slitter blades, one may also use, for example, scoring blades which are also known in the pertinent art and comprise a plurality of circular blades which ride against a resilient surface. Other similar severing means taught in the prior art are also adaptable for use as severing means 14. Ordinarily, the individual cutting or severing blades comprising severing means 14 will be of an equidistant separation of from about 0.5 to about 5.0 inches and preferably from about 1.0 to about 2.0 inches.

Continuous parallel strips of material exiting from severing means 14 are cross-lapped onto a second conveyor means 16 by traversing means 18.

In the preferred embodiment, traversing means 18 is an endless conveyor belt having an internal vacuum source. One end of the conveyor belt is adjacent severing means 14 while the other end of the conveyor belt is adjacent conveyor means 16. Strips carried by traverse means 18 are held onto the conveyor surface by an internal vacuum source until reaching the end of the conveyor belt closest to conveyor means 16. Traversing means 18 is adapted to pivot about the end closest to severing means 14 and oscillate across the surface of conveyor 16, preferably at a distance of from about 6 to about 8 inches.

It is not essential to the present invention that traversing means 18 be of the particular type illustrated. Instead, one may also suitably employ dual opposed conveyor belts disposed to oscillate over conveying means 16 and convey the sheet material therebetween. Also, an oscillatable chute known in the art as a plaiter may be employed for this purpose. Other suitable alternatives will be readily apparent to the skilled artisan. In fact, in some instances, it is possible to eliminate traversing means 18 entirely by using as conveyor means 16 an endless conveyor belt adapted for transverse oscillation.

Strips cross-lapped onto conveyor means 16 are conveyed to a second severing zone 20 where the strips are severed generally transversely to form discrete pieces having a parallelogram configuration. Severing means 20 will generally, but not necessarily, be of the same structure as severing means 14. The preceding description of severing means 14 is equally applicable to severing means 20.

Discrete pieces of sheet material exiting from severing means 20 fall into receptacle 22 or may be otherwise collected for subsequent processing, storage, or shipping.

It is to be understood that the foregoing detailed description is given by way of illustration and that many variations may be made therein without departing from the spirit and scope thereof.

What is claimed is:

l. A process for continually severing a continuous flexible sheet material into discrete pieces of a para]- lelogram configuration com prising:

a. continually conveying in a first direction an endless sheet of a flexible material to a first severing zone;

b. longitudinally severing said material into continuous parallel strips;

0. cross-lapping said strips onto a surface moving in a second direction generally transverse to said first direction and d. transversely severing said strips to form said discrete pieces.

2. The process of claim 1 wherein said flexible material isasmokable sheet material.

3. e process of claim 1 wherem said sheet is severed into parallel strips having a width of from about 1 to about 5 inches.

4. The process of claim 1 wherein said strips are severed into discrete pieces having a parallelogram configuration of about 1 to about 5 inches on each side.

5. An apparatus for converting a continuous sheet of flexible material into discrete pieces having a parallelogram configuration comprising:

a. a first conveying means for continually conveying a flexible sheet material along a first path in a first given direction;

b. a first severing means positioned along said first path and transverse to said first given direction adapted to sever said material into a plurality of parallel strips;

c. a second conveying means positioned transversely of said first conveying means for conveying material along a second path in a second given direction;

d. traversing means located between said first and second conveying means adapted to cross lap said parallel continuous strips onto said second conveying means;

e. a second severing means positioned along said second path and transverse to said second given direction adapted to sever said parallel continuous strips into discrete pieces having a parallelogram configuration; and

f. a receptacle for receiving said pieces.

6. The apparatus of claim 5 wherein said flexible sheet material is a smokable sheet material.

7. The apparatus of claim 5 wherein said first and second conveying means are endless conveyor belts having a width of from about 24 to about 72 inches.

8. The apparatus of claim 5 wherein said first and second severing means are comprised of parallel slitter blades positioned at a distance of from about 1 to about 5 inches apart.

9. The apparatus of claim 5 wherein said traversing means is an endless conveyor belt with an internal vacuum source having one end adjacent to said first severing means and the other end adjacent to said second conveying means and adapted to oscillate across said second conveying means. 

1. A process for continually severing a continuous flexible sheet material into discrete pieces of a parallelogram configuration comprising: a. continually conveying in a first direction an endless sheet of a flexible material to a first severing zone; b. longitudinally severing said material into continuous parallel strips; c. cross-lapping said strips onto a surface moving in a second direction generally transverse to said first direction and d. transversely severing said strips to form said discrete pieces.
 1. A process for continually severing a continuous flexible sheet material into discrete pieces of a parallelogram configuration comprising: a. continually conveying in a first direction an endless sheet of a flexible material to a first severing zone; b. longitudinally severing said material into continuous parallel strips; c. cross-lapping said strips onto a surface moving in a second direction generally transverse to said first direction and d. transversely severing said strips to form said discrete pieces.
 2. The process of claim 1 wherein said flexible material is a smokable sheet material.
 3. The process of claim 1 wherein said sheet is severed into parallel strips having a width of from about 1 to about 5 inches.
 4. The process of claim 1 wherein said strips are severed into discrete pieces having a parallelogram configuration of about 1 to about 5 inches on each side.
 5. An apparatus for converting a continuous sheet of flexible material into discrete pieces having a parallelogram configuration comprising: a. a first conveying means for continually conveying a flexible sheet material along a first path in a first given direction; b. a first severing means positioned along said first path and transverse to said first given direction adapted to sever said material into a plurality of parallel strips; c. a second conveying means positioned transversely of said first conveying means for conveying material along a second path in a second given direction; d. traversing means located between said first and second conveying means adapted to cross lap said parallel continuous strips onto said second conveying means; e. a second severing means positioned along said second path and transverse to said second given direction adapted to sever said parallel continuous strips into discrete pieces having a parallelogram configuration; and f. a receptacle for receiving said pieces.
 6. The apparatus of claim 5 wherein said flexible sheet material is a smokable sheet material.
 7. The apparatus of claim 5 wherein said first and second conveying means are endless conveyor belts having a width of from about 24 to about 72 inches.
 8. The apparatus of claim 5 wherein said first and second severing means are comprised of parallel slitter blades positioned at a distance of from about 1 to about 5 inches apart. 